Note: Descriptions are shown in the official language in which they were submitted.
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FASTENING A CEILING TRIM
This invention relates to a method and arrangement for fastening a
ceiling trim to a wall at the junction between the ceiling and the wall. The
trim
therefore simulates or acts as a crown molding covering the junction between
the
drywall at the ceiling and wall. The trim can provide a conduit for wiring,
fiber optics,
pipes or other continuous members.
BACKGROUND OF THE INVENTION
Typically crown moldings are fastened to a wall by finishing nails
which then require to be patched with a filler and finish painted over the
filler. Thus
in most cases the boards are supplied in a prime paint condition so that the
finish
coat is applied simultaneously over the filler and the prime coat. This
requires
considerable labor to fill and paint the small holes left by the finish nails.
Also
painting of different colors on the ceiling, on the crown molding and on the
wall
require careful attention along the joining lines to ensure an acceptable
finish which
does not transfer from one surface to the other.
It is well known that separation between the horizontal roof or ceiling
rafters and the wall studs can occur which tends to lift the drywall attached
to the
ceiling rafters away from the drywall attached to the wall studs to form an
unsightly
crack
Crown moldings are typically made from solid wood or wood product or
from a foam material which simulates the wood product.
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Attempts have been made to apply extruded components to this area
as a simpler way to finish the corner.
US Patent 5,836,113 (Bachman) issued November 17 1998 discloses
a system for finishing exterior siding where a conventional J-channel bracket
is
mounted on a surface at corner to locate the soffit panel at the top panel of
the
siding and receives a snap in trim piece.
US Patent 7,200,970 (Koenig) issued April 10 2007 discloses a one
piece extrusion which attaches to the ceiling at the corner and includes a
horizontal
top piece, an inclined piece forming the appearance of the crown molding and a
bottom lip on the inclined piece which fastens to the wall and is covered by a
plaster
layer.
US Patent 1,825,010 (Murphy) issued September 29 1931 discloses
an electrical conduit fastened at the corner of wall and ceiling where a first
right
angle piece fastens to the corner and is covered by an arched piece to define
the
hollow interior as a conduit.
US Patent 6,115,982 (Lindenberg) issued September 12 2000
discloses a two piece system where a first bracket piece is mounted on a
surface at
corner to locate a panel and receives a snap in trim piece which has a leg
engaging
into a slot.
US Patent 5,426,901 (Indracek) issued June 27 1995 discloses a
crown molding system including two strips which fasten to the wall and ceiling
respectively and a shaped inclined piece which snaps onto the two strips.
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US Patent 5,433,048 (Strasser) issued July 18 1995 discloses a crown
molding system a generally right angle piece which fastens to the wall and
ceiling
respectively to define flanges which extend at right angles to the wall and
ceiling
respectively and engage into slots in a molded foam crown molding piece to
attach
the piece to the corner.
SUMMARY OF THE INVENTION
It is one object of the invention to provide an improved arrangement for
forming a ceiling trim.
According to the invention there is provided a set of extruded
components for forming a crown molding ceiling trim for location at a junction
between a wall and a ceiling comprising:
a first extruded component defining, in an integral constant cross-
section:
an angle member having a first leg for engaging the ceiling and
a second leg for engaging the wall with the legs meeting at a corner portion;
each of the first and second legs having a respective in-turned
first and second clip portion at a position spaced from the corner portion;
and a second extruded component defining, in an integral constant
cross-section:
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a front face portion forming a required shape of the crown
molding and having a first side edge thereof arranged to be located at or
closely
adjacent the ceiling and a second side edge thereof arranged to be located at
or
closely adjacent the wall;
a first strip member spaced inwardly from the first edge for
engaging behind the first clip portion of the first leg;
and a second strip member spaced inwardly from the second
edge for engaging behind the second clip portion of the second leg;
the second extruded component being held in place by engagement
between the first strip member and the first clip portion and between the
second strip
member and the second clip portion with the front face portion inclined
between the
clip portions.
Preferably the first component is flexible at the corner portion so as to
allow an angle between the legs to be adjusted.
Preferably the first component is curved at the corner portion so as to
allow an angle between the legs to be adjusted.
Preferably the first extruded component is attached to the wall and/or
ceiling by penetrating fasteners engaged through one or both of the legs
thereof.
However other fasteners can be used including tape and by mudding in a strip
of the
first component onto the wall or ceiling.
Preferably each strip member is arranged to engage the respective clip
portion at a plurality of spaced positions so that a distance of the second
component
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from the junction between the wall and ceiling can be adjusted. In one example
each strip member can have a plurality of v-shaped receptacles at spaced
positions
along its length and the clip portion includes a pointed end to engage into a
selected
one of the receptacles. However other adjustments systems between the mounting
5 clip portions and the strip members can be used.
Preferably the second component is arranged to engage and be
supported by the first component so that side edges thereof lie immediately
adjacent
but spaced from the wall or ceiling. This position can be adjusted by the
adjustment
system above to provide a required spacing.
Preferably is provided a mounting on the first component for carrying
behind the second component a lighting strip so that the light from the strip
is visible
on the wall and the ceiling at the spaced side edges of the second component.
Preferably the strip members are perforated so that the light from the
lighting strip located between the strip members centrally of the second
component
passes through the strip members and is visible on the wall and the ceiling at
the
side edges of the second component.
Preferably there is provided a plurality of separate clips for mounting at
spaced positions along the first component and wherein the first component
includes
fastening elements for engaging and supporting the clips so that the clips are
supported at a position behind the second component. This can be used to carry
wires or other elongate components where the wires are collated on a support
such
as the floor with the clips engaged onto the wires and lifted from the floor
to the first
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installed component to allow the clips to be readily inserted to hold the
wires in the
first component to be covered by the second component.
Preferably the fastening elements comprise a track along the first
component with each clip having a pair of engagement elements for engagement
into the track at a selected location thereon.
Preferably each clip comprises a ring through which a cable can be
inserted where the ring is open at a rear thereof with a pair of engagement
elements
at the rear for engaging the fastening elements and holding the ring closed on
the
first component.
Preferably the clip portion of the first component which mounts the
second component extends contiguously from an end of the respective leg and is
arched therefrom to an end tip for engaging the respective strip member.
Preferably the strip members are parallel and extend rearwardly from a
rear face of the second component.
Preferably the first component includes, as a separate item for
cooperation therewith, a third component defining, in an integral constant
cross-
section, a dividing member which can be engaged into position extending across
between the legs behind the second component so as to provide a separate
compartment of the first component at the corner portion forming a conduit.
Preferably the third component comprises a strip with two side edges
each of which is arranged to engage behind a flange on a respective one of the
legs.
The strip can be flat or domed.
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Preferably there is provided a plurality of separate clips for mounting at
spaced positions along the third component and the third component includes
fastening elements for engaging and supporting the clips so that the clips are
supported at a position behind the second component. In addition to cooperate
with
the same mounting flanges for the third component, there is preferably
provided a
plurality of separate clips for mounting at spaced positions along the first
component
and the clips are arranged to engage the flanges when the third component is
omitted so that the clips are supported at a position behind the second
component.
According to a second aspect of the invention there is provided a set of
extruded components for forming a crown molding ceiling trim for location at a
junction between a wall and a ceiling comprising:
a first extruded component defining, in an integral constant cross-
section:
an angle member having a first leg for engaging the ceiling and
a second leg for engaging the wall with the legs meeting at a corner portion;
a second extruded component defining, in an integral constant cross-
section:
a front face portion forming a required shape of the crown
molding and having a first side edge thereof arranged to be located at or
closely
adjacent the ceiling and a second side edge thereof arranged to be located at
or
closely adjacent the wall;
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the second extruded component being held in place by cooperating
fastening elements between the first component and the second component with
the
front face portion held inclined between the ceiling and the wall;
wherein the fastening elements are arranged to provide a plurality of
separate adjustment positions so that a distance of the second component from
the
junction between the wall and ceiling can be adjusted.
According to a third aspect of the invention there is provided a set of
extruded components for forming a crown molding ceiling trim for location at a
junction between a wall and a ceiling comprising:
a first extruded component defining, in an integral constant cross-
section:
an angle member having a first leg for engaging the ceiling and
a second leg for engaging the wall with the legs meeting at a corner portion;
a second extruded component defining, in an integral constant cross-
section:
a front face portion forming a required shape of the crown
molding and having a first side edge thereof arranged to be located at or
closely
adjacent the ceiling and a second side edge thereof arranged to be located at
or
closely adjacent the wall;
the second extruded component being held in place by cooperating
fastening elements between the first component and the second component with
the
front face portion held inclined between the ceiling and the wall;
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wherein there is provided a plurality of separate clips for mounting at
spaced positions along the first component and wherein the first component
includes
fastening elements for engaging and supporting the clips so that the clips are
supported at a position behind the second component.
According to a fourth aspect of the invention there is provided a set of
extruded components for forming a crown molding ceiling trim for location at a
junction between a wall and a ceiling comprising:
a first extruded component defining, in an integral constant cross-
section:
an angle member having a first leg for engaging the ceiling and
a second leg for engaging the wall with the legs meeting at a corner portion;
a second extruded component defining, in an integral constant cross-
section:
a front face portion forming a required shape of the crown
molding and having a first side edge thereof arranged to be located at or
closely
adjacent the ceiling and a second side edge thereof arranged to be located at
or
closely adjacent the wall;
the second extruded component being held in place by cooperating
fastening elements between the first component and the second component with
the
front face portion held inclined between the ceiling and the wall;
wherein the first component includes a third component defining, in a
separate integral constant cross-section, a dividing member which can be
engaged
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into position extending across between the legs behind the second component so
as
to provide a separate compartment of the first component at the corner portion
forming a conduit.
5 The
term "corner" set forth above is not intended to be limited to a right
angle corner between the two leg portions and the junction therebetween may be
curved or diagonal or any shape which simply connects the two legs adjacent
the
junction between the wall and ceiling.
In some cases each clip member is defined by a simple in-turned
10
flange but any shape may be used which can receive and locate the edge piece
of
the second extruded member.
Where the simple flat flange arrangement is used, these flanges can
be inclined so that the angle between an inside surface of the flange and the
respective leg is less than 90 degrees.
In some cases there is provided at least one strip of adhesive material
arranged to attach the first extruded component to the wall and or ceiling to
be held
in place while the skimming plaster material is applied. The adhesive material
can
be a layer of two sided pressure sensitive carried on the second extruded
component with a release sheet covering. The adhesive material is preferably
located on the second leg adjacent the corner allowing the right angle member
to be
pressed into the junction. In some cases, the adhesive material can include a
second optional strip of adhesive located on the first leg adjacent the outer
strip
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portion. As an alternative, beads of adhesive can be applied immediately
before the
component is applied to the wall and before the skimming plaster material is
applied.
In all cases the first component can also be fastened to the wall/ceiling by
penetrative fasteners such as screws, nails or staples.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the invention will now be described in conjunction
with the accompanying drawings in which:
Figure 1 is an end elevational view of two extruded components of a
system for forming a ceiling trim using the arrangement of the present
invention.
Figure 2 is an isometric view of the components of Figure 1.
Figure 3 is a cross-sectional view of the first component of Figure 1.
Figure 4 is a cross-sectional view of the second component of Figure
1.
Figure 5 is a cross-sectional view of a clip as used in Figure 1.
Figure 6 is a cross-sectional view of the third component of Figure 1.
Figure 7 is a cross-sectional view of the components of Figure 1 when
used to provide an illumination at the edges of the ceiling trim.
Figure 8 is a cross-sectional view of some the components of Figure 1
when used without the third component and with a second form of clip.
DETAILED DESCRIPTION
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As shown in Figure 1 and 7, crown molding 10 is formed at the junction
11 between a ceiling 12 and a wall 13 where the ceiling and wall are formed by
layers of dry-wall applied over wall studs and roof rafters. The crown molding
system comprises extruded components for forming for location at the junction
11
between the wall 13 and the ceiling 12.
The system includes a first extruded component 20 defining, in a
constant cross-section, a generally right angle member having a first leg 21
for
engaging the ceiling and a second leg 22 for engaging the wall with the legs
meeting
at a corner portion 24. Each of the first and second legs 21 and 22 has a
respective
in-turned clip member 23 or flange at a position spaced from the corner 24.
The system further includes a separate second extruded component
30 defining, in a constant cross-section, cover strip having a front face
portion 31
forming a required shape of the crown molding. This is shown as a simple arch
but
can be of any aesthetic shape with sufficient stiffness to retain its shape
when
carried at the junction.
The second component includes first side edge strip portion 32 for
engaging the clip member or flange 23 of the first leg 21 and a second strip
portion
33 for engaging the clip member or flange of the second leg. Thus the strip
portions
are arranged to engage behind the flanges 23 to hold the second component in
place by its clipping action. The strip portions can be arranged to lie at a
common
angle with the flanges 23 so as engage behind them and lie flat against them.
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However other shapes including edge beads or hook elements can be used as
shown in Figure 7 and described in more detail hereinafter.
The second extruded component is typically but not essentially resilient
such that it is deformable to squeeze the strip portions 32, 33 inwardly by
bending or
flexing slightly the piece 31 toward one another to engage into the clip
members 23
and such that when released from squeezing the flexibility of the piece 31
causes
the component 30 to bridge between the clip members to be held in place with
the
front face portion generally inclined between the clip members.
A strip 40 of adhesive material in the form of a layer of two sided
pressure sensitive with a release sheet is carried on the second extruded
component on the leg 21 adjacent the corner 24.
This allows the right angle
member to be pressed into the junction. An optional second strip of adhesive
material can be located on the first leg 22.
A tool can be provided to cut the second component 30 to length while
in situ including providing miter joints where necessary at corners in the
wall.
The flexibility of the second component allows it to remain in place and
to hide any flexing of the ceiling which may occur during settling or
temperature
changes which would normally be expected to generate visible cracks in non-
flexible
systems.
Thus the first component 20 is a right angle piece fastened to the wall
by nail or screw fastener 202 engaged into the wall through the leg 22 at a
position
inward of the clip 23, that is, closely adjacent the corner. The leg 21 can be
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fastened to the ceiling by the tape 40 or by a nail or screw fastener engaged
into the
ceiling through the leg 21 at a position inward of the clip 23, that is spaced
away
form the corner. This holds the first component into the junction with any
movement
of the ceiling being taken up by flexing.
The second component 301 is substantially as previously described
and includes strip portions 32 and 33 as previously described with engage
behind
the clip 23. Since there is no mud applied in this embodiment because the wall
and
ceiling are already finished, the portions of the first component extending
beyond the
clips 23 would be exposed and hence it is necessary to provide a second
component 30 with additional edge strips 302 and 303 with ends 304 and 305
which
butt the wall and ceiling respectively at a position at or slightly beyond the
end of the
first component 20. In most cases the ends 304, 305 are spaced slightly from
the
wall to allow for slight inaccuracies in the dry walling and prevent unsightly
changes
of the edges being in contact or no contact with the wall.
The flexibility of the component 20 at the corner portion 24 defined by
the curvature of the corner portion and the use of thinner material at this
location
allows the components for use in a vaulted ceiling where the angle between the
wall
and the ceiling is greater than 90 degrees. That is the first component 20 can
flex to
lie at any selected angle less than, equal to and greater than 90 degrees as
required
so that the leg 22 lies flat against the wall and the leg 21 lies flat against
the ceiling.
As the angle of the legs 21 and 22 is in a vaulted ceiling greater than 90
degrees,
the distance between the clip members 23 is now greater than in the 90 degree
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arrangement of Figure 7. Thus the second component 30 is allowed to expand
under its natural spring to span the full width of the clip members 23. Thus
it will be
appreciated that the cover strip 30 is flexible so that its edges can be
squeezed
toward one another for either the clip pieces 32 and 33 to be used for
clipping.
5 In
Figure 7 the ends 304 and 305 of the edge pieces 302, 303 butt
against the applied plaster layer 26 outside of the clip members 23. The cover
strip
is of course flexible so that the edge pieces 32 and 33 can flex to engage the
clip
members 23 when the extra edge pieces are moved to a required position to butt
the
plaster 26.
As the edges 304 and 305 define the visible side edges of the cover
10 strip, avoiding flexing at this location allows the extra edge pieces to
form straight
edges or lines along the corner.
The second component 30 includes a pair of rearwardly extending legs
or strip portions 32, 33 each for frictionally engaging a respective one of
the clip
members 23. The clip members are shaped to define end abutments 23A, 23B
15 which butt against the outside surface of the legs 32, 33.
Each leg has on its outer face arranged to engage the respective clip
member a plurality of ribs or v-shaped recesses 32A, 33A so as to engage the
pointed tip 23A, 23B at a plurality of spaced defined positions so that a
distance of
the second component 30 from the corner can be adjusted as indicated at the
arrows A.
Each of the clip portions 23 extends contiguously from an end of the
respective leg 21, 22 and is arched or smoothly curved therefrom through
roughly
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180 degrees to the pointed end tip for engaging the respective strip member.
The
strip members 32, 33 are parallel and extend rearwardly from the rear face of
front
panel 31 the second component 30.
Thus the second component 30 is arranged to engage and be
supported by the first component 20 so that its side edges 304, 305 thereof
lie
immediately adjacent but spaced from the wall or ceiling. The space can be
adjusted to provide a constant appearance at the edge of the second component
so
that slight distortion of the second component can take up any inaccuracies in
the
application of the drywall or studs/joists while maintaining a constant
appearance
along the full length of the ceiling trim.
In addition to providing an attractive appearance, the system can also
be used for retro-fitting cable C and/or cable D. Thus in this case, the first
component 20 includes fastening elements in the form of a track 40 for
engaging
and supporting a plurality of clips 41 attached at spaced positions along the
first
component 20 at a position behind and hidden by the second component 30.
The fastening elements comprise inwardly facing angle strips 40A, 40B
defining the track along the first component. Each clip 41 comprises a ring 42
through which the cable D can be inserted open at a rear 42Athereof to allow
the
ring to be opened and threaded over the cable.
In this way the cable can be strung in the required route, merely
draped on the floor and then the rings 42 can be engaged over the cable at the
required spacings. The ring at the opening has a pair of engagement elements
43,
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44 at the rear for engaging into the strips 40A, 40B of the track 40 and
holding the
ring 42 in closed position attached to the track. The opening 42A at the rear
allows
the ring to be squeezed enough to allow the elements 43, 44 to engage into the
track with the spring of the plastic ring holding the opening apart and the
elements in
engagement with the track.
With the cable D thus strung in place on the clips within the first
component 20, the second component 30 can be clipped into place by engagement
between the legs 32, 33 and the clips 23 and moved to the required location
slightly
spaced from the wall and ceiling.
The location of the cable at the ceiling avoids the interference with
windows of doors which would occur if applied at the floor. Thus it is
generally
simple to string the cable around the wall and to pass from room to room
through a
hole H drilled through the wall at the location of the leg 22.
The second extruded component 30 is thus held in place by
engagement between the first strip member 32 and the first clip portion 23 and
between the second strip member 33 and the second clip portion 23 with the
front
face portion 31 inclined between the clip portions.
As shown in Figure 7 the mounting clip 41 on the first component 20
can be used for carrying behind the second component 30 a lighting strip LS so
that
the light from the strip LS is visible on the wall and the ceiling at the side
edges 304,
305 of the second component 30. In order to allow the light from the strip LS,
which
may be a commercially available LED strip, to reach the wall and ceiling at
the space
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from the edges 304, 305, the legs or strip portions 32, 33 are perforated with
slots
308, 309 at the front face 31.
There is also provided a third component 60 defining, in an integral
constant cross-section, a dividing member 61 which can be engaged into
position
extending across between the legs 21 and 22 behind the second component 30 so
as to provide a separate compartment 62 of the first component 20 at the
corner
portion 24 thereby forming a conduit for the cable C. The third component
comprises a strip with two side edges 63, 64 each of which is arranged to
engage
behind a flange 263, 264 on a respective one of the legs 21, 22. The side
edges 63,
64 can be fastened into place by insertion behind the flanges or by adhesive
tape
265 or by a screw fastener 266 which provide more security to deter persons
from
accessing the compartment 62 to protect the cable C.
As shown in Figure 7, the track 40 is located on the third component
60 so as to provide the compartment for cable C and the clips for cable D.
As shown in Figure 8, there is provided a plurality of separate clips 70
for mounting at spaced positions along the first component 20 and the clips
are
arranged to engage the flanges in replacement for the third component when it
is
removed so that the clips 70 are supported at a position behind the second
component.
